WO2007064373A1 - Convertisseur catalytique - Google Patents

Convertisseur catalytique Download PDF

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Publication number
WO2007064373A1
WO2007064373A1 PCT/US2006/031660 US2006031660W WO2007064373A1 WO 2007064373 A1 WO2007064373 A1 WO 2007064373A1 US 2006031660 W US2006031660 W US 2006031660W WO 2007064373 A1 WO2007064373 A1 WO 2007064373A1
Authority
WO
WIPO (PCT)
Prior art keywords
catalytic converter
channel
foil
channels
linear
Prior art date
Application number
PCT/US2006/031660
Other languages
English (en)
Inventor
Craig F. Habeger
Michael J. Pollard
Original Assignee
Caterpillar Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Caterpillar Inc. filed Critical Caterpillar Inc.
Priority to DE112006003187T priority Critical patent/DE112006003187T5/de
Publication of WO2007064373A1 publication Critical patent/WO2007064373A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F01N3/2814—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates all sheets, plates or foils being corrugated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F01N3/2821—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates the support being provided with means to enhance the mixing process inside the converter, e.g. sheets, plates or foils with protrusions or projections to create turbulence
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49345—Catalytic device making

Definitions

  • the present disclosure relates to a catalytic converter, an exhaust system of an internal combustion engine comprising a catalytic converter, and a method for manufacturing a catalytic converter. More particularly, the present disclosure relates to a catalytic converter that is configured to partially catalyze at least a portion of unwanted combustion byproducts that are emitted from the exhaust system of an internal combustion engine.
  • a catalytic converter is a device that uses a chemical catalyst to help convert various harmful emissions of the engine's exhaust into harmless — or less harmful — chemical compounds. As previously mentioned, some of these harmful emissions include hydrocarbons, NOx, and carbon monoxide.
  • Some catalytic converters are manufactured from a ceramic structure, such as a honeycomb, which is then coated with a catalyst and later housed in a muffler-like package attached to an exhaust pipe.
  • Other catalytic converters comprise metallic foils, which are then rolled about an axis to form a cylindrical structure, which is then housed in a muffler-like package attached to the exhaust pipe. In these rolled catalytic converters, the catalyst may be applied either before or after the foils are wound together.
  • the converter usually comprises numerous neighboring channels, through which exhaust gas flows.
  • Most catalytic converters are coated with a chemical catalyst. These catalysts may comprise a precious metal, such as rhodium, platinum, and palladium, for example. Some catalysts, for example, help to convert carbon monoxide into carbon dioxide. Other catalysts may help to convert hydrocarbons into carbon dioxide and water, while even other catalysts may help to convert NOx into nitrogen and oxygen. If the catalytic converter is made from a ceramic substrate, the converter may be manufactured by extrusion, which results in channels having straight channels along their entire length.
  • the catalytic converter is made from metal, corrugated strips or foils are alternatively arranged with flat strips, both of which are then wound around an axis or around multiple axes such as the Emitec design.
  • the resulting channel cross-sectional shape is usually rectangular or trapezoidal.
  • the resulting channels in metal converters are also typically straight along their entire length. Because many of the catalytic converters of either the ceramic or metallic type have generally straight channels, with smooth and even surfaces, and the velocities of the gases that flow through them are relatively low, the flow within the channels is oftentimes laminar.
  • a boundary layer is formed closest to a channel wall. At this boundary layer, the velocity of the gas is near zero. As a result, the boundary layer reduces the coefficient of mass transfer, which may reduce the catalytic converter efficiency.
  • a measure of the catalytic converter's efficiency depends on the conversion of harmful emissions within the converter. As such, it is desirable to have a highly efficient converter. Generally, in order for the catalytic converter to have a high efficiency, the coefficient of mass transfer, which measures the mass transfer rate, must also be high.
  • the flow of exhaust gas through the channels may be changed from laminar flow to turbulent flow, although this typically increases the pressure drop across the filter.
  • Turbulent flow may be created in several different ways. For instance, the velocity of the exhaust gas may be substantially increased, which will generate turbulent flow in the channels. Alternatively, arranging the channels so that they are not straight along their entire lengths may also create turbulent flows.
  • Nilsson discloses a turbulence inducer in a catalytic converter channel.
  • a catalytic converter comprising longitudinal channels is disclosed.
  • the channels have first and second turbulence generators spaced apart in the longitudinal direction for making the gas flow turbulent.
  • each turbulence generator includes a rear face inclined forwardly at an angle of from 35° to 60° from a base of the channel and facing rearwardly, a connecting face extending forwardly from a free edge of the rear face, and a front face projecting toward the base from a front edge of the connecting face and facing forwardly.
  • Nilsson teaches using turbulence inducers to create turbulent flow in at least part of a catalytic converter channel
  • the cost-of-manufacture of the Nilsson catalytic converter may be prohibitively expensive.
  • the flow within the entire length of the channel of Nilsson may still maintain laminar characteristics, depending on several factors, including the spacing between the turbulence generators.
  • the present disclosure is directed to overcoming one or more of the problems or disadvantages existing in the prior art.
  • a catalytic converter may comprise at least one channel configured to receive gas flow and a catalyst coated on the at least one channel.
  • the at least one channel is at least partially non-linear along its length.
  • an exhaust system of an internal combustion engine may comprise an exhaust pipe in fluid communication with an exhaust manifold of the internal combustion engine, a housing in fluid communication with the exhaust pipe, and a catalytic converter housed within the housing.
  • the catalytic converter may comprise at least one channel configured to receive gas flow and a catalyst coated on the at least one channel.
  • the at least one channel may be non-linear along at least part of the channel length.
  • the exhaust system may also be in which the catalytic converter is configured to at least partially catalyze an exhaust constituent.
  • a method of manufacturing a catalytic converter may comprise the steps of providing at least one first metal foil, the first metal foil being substantially flat, providing at least one second metal foil, the second metal foil comprising non-linear channels, and wrapping the at least one first metal foil and the at least one second metal foil around an axis.
  • the method may comprise the steps of providing at least one foil, the foil comprising non-linear channels, and wrapping the at least one foil around an axis.
  • Fig. 1 is a perspective view of a catalytic converter foil with non- linear channels
  • Fig. 2 is a schematic top view of part of the catalytic converter foil of Fig. 1;
  • Fig. 3 is a schematic cross-sectional front view of part of the catalytic converter foil of Fig. 1;
  • Fig. 4 is a perspective view of two catalytic converter foil with non-linear channels alternatively interposed between two flat foils;
  • Fig. 5 is a perspective view of a catalytic converter foil with nonlinear channels partially rolled about an axis
  • Fig. 6 is a perspective view of two catalytic converter foils with non-linear channels partially rolled about an axis along with two flat foils;
  • Fig. 7 is a perspective view of exhaust gas flowing through a particular embodiment of a catalytic converter.
  • Fig. 1 is a perspective view of a catalytic converter foil 10 with non-linear channels 16.
  • channels 16 are sinusoidal in shape along the entire length of channels 16.
  • Channels 16 are configured to receive fluid flow, such as exhaust gas 40 fluid flow, when formed as part of a catalytic converter 30 (shown in Fig. 7).
  • the non-linear nature of channels 16 promotes turbulent fluid flow, which oftentimes increases the efficiency of the chemical catalyst.
  • channels 16 in Figs. 1-7 are sinusoidal, the reader should appreciate that any non-linear channel 16 may be used.
  • channels 16 may comprise sharp corners, irregular contours that are inconsistent with a typical sine wave, and any other non-linear shape, so long as turbulent flow is generated in at least part of channel 16.
  • channel 16 need not be present during the entire length of channel 16.
  • Figs. 1-7 depict a non-linear wave being present along the entire length of channel 16, the disclosed embodiments are not limited to this structure.
  • channel 16 may include non-linear waves, bends, contours, or curves, for example, for only part of the length of channel 16. During the remainder of channel 16, channel 16 may be straight.
  • Fig. 2 depicts a partial top view of foil 10.
  • foil 10 comprises sinusoidal channels 16 with amplitude 11 and period 12. In at least one embodiment, amplitude 11 is about .25 inches or less and period 12 is about 2.0 inches or less.
  • catalytic converter 30 is not limited to require channels 16 with sinusoidal shapes, as depicted, but may include any non-linear shape that promotes turbulent fluid flow.
  • Fig. 3 a partial front cross-sectional view of foil 10 is shown.
  • foil 10 in addition to having sinusoidal channels 16 (shown in Fig. 1), is also rippled along its end.
  • the ripples have radius 15, amplitude 13, and period 14.
  • the radius 15 is about .038 inches
  • amplitude 13 is about .15 inches or less
  • period 14 is about .15 inches or less.
  • Fig. 3 provides specific values for radius 15, amplitude 13, and period 14, the reader should appreciate that several different values may be used in the design of foil 10 and channels 16 (shown in Fig. 1).
  • catalytic converter 30 is not limited to require channels 16 with semi-circular or rippled cross sections, as depicted in Fig. 3, but may include any cross-sectional shape.
  • channels 16 may include polygonal cross-sectional shapes, such as trapezoidal, rectangular, or triangular shapes, just to name a few.
  • catalytic converter 30 may be manufactured in several different ways.
  • foil 10 may be rolled up to form the cylindrical catalytic converter 30, which is depicted in Fig. 7.
  • axis 17 of the rolled converter 30 is substantially parallel to the direction of non-linear channels 16.
  • foil 10 may also be rolled together about axis 17 such that axis 17 is not substantially parallel to the direction of non-linear channels 16.
  • foil 10 may be rolled about axis 17 such that the direction of channels 16 is offset at some angle with respect to axis 17.
  • converter 30 is capable of receiving exhaust flow 40 from one end 31 and sending exhaust gas to the other end 32, channels 16 may be aligned in any possible manner with respect to axis 17.
  • any number of foils 10 may be rolled together around axis 17 to form catalytic converter 30.
  • two, three, four, or five foils 10 may be rolled together to form catalytic converter 30.
  • catalytic converter 30 may alternatively be manufactured by placing two flat foils 20 adjacent to two sinusoidal foils 10.
  • foils 10 and 20 are rolled together about axis 17, such that axis 17 is substantially parallel to the direction of sinusoidal channels 16.
  • foils 10 and 20 may also be rolled together about axis 17 such that axis 17 is not substantially parallel to the direction of sinusoidal channels 16.
  • foil 10 and or foil 20 may be composed of any material that is known to one skilled in the art, including flexible materials.
  • foil 10 and foil 20 are composed of similar metals.
  • foils 10 and 20 comprise aluminum.
  • foil 10 and or foil 20 may also be coated with a catalyst, such as palladium, rhodium, and or platinum, for example.
  • foils 10 and 20 are both coated with the same chemical catalyst.
  • catalysts that catalyze several different exhaust components that may be used in the disclosed converters 30.
  • One skilled in the art would understand that the disclosed embodiments are not limited to catalyzing only hydrocarbons, carbon monoxides, and NOx.
  • catalytic converter 30 can be used in many different applications, including in the exhaust stream of an internal combustion engine.
  • catalytic converter 30 may be placed in a cylindrical housing (not shown) that receives exhaust gas 40 from an exhaust manifold of the engine.
  • exhaust gas 40 may be partially or fully catalyzed before being emitted into the environment or recirculated back into the engine's intake system — for engines with exhaust gas recirculation, for instance.
  • exhaust gas 40 flows from left-to-right through catalytic converter 30.
  • exhaust gas 30 may have unwanted constituents, such as hydrocarbons, carbon monoxides, and or NOx, for example.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

Convertisseur (30) catalytique, système d'échappement comportant un convertisseur (30) catalytique et procédé de fabrication d'un convertisseur (30) catalytique. Le convertisseur (30) catalytique comporte au moins un canal (16) configuré pour recevoir un écoulement (40) de gaz et un catalyseur revêtant ledit au moins un canal (16). Dans l'un des modes de réalisation décrits, ledit au moins un canal (16) du convertisseur (30) catalytique est de forme non-linéaire.
PCT/US2006/031660 2005-11-29 2006-08-14 Convertisseur catalytique WO2007064373A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE112006003187T DE112006003187T5 (de) 2005-11-29 2006-08-14 Katalytischer Wandler

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/289,213 US20070122318A1 (en) 2005-11-29 2005-11-29 Catalytic converter
US11/289,213 2005-11-29

Publications (1)

Publication Number Publication Date
WO2007064373A1 true WO2007064373A1 (fr) 2007-06-07

Family

ID=37307317

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/031660 WO2007064373A1 (fr) 2005-11-29 2006-08-14 Convertisseur catalytique

Country Status (4)

Country Link
US (1) US20070122318A1 (fr)
CN (1) CN101316995A (fr)
DE (1) DE112006003187T5 (fr)
WO (1) WO2007064373A1 (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8357427B2 (en) * 2009-02-12 2013-01-22 International Engine Intellectual Property Company, Llc Preparation method for a partially coated monolith
US20120222412A1 (en) * 2011-03-02 2012-09-06 International Truck Intellectual Property Company, Llc Engine Exhaust Gas Particulate Filter having Helically Configured Cells
US10598068B2 (en) * 2015-12-21 2020-03-24 Emissol, Llc Catalytic converters having non-linear flow channels
US10287952B2 (en) * 2016-03-30 2019-05-14 Denso International America, Inc. Emissions control substrate

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5843238A (ja) * 1981-09-10 1983-03-12 Ngk Spark Plug Co Ltd セラミツクハニカム構造体とその製造法
EP0154516A2 (fr) * 1984-02-28 1985-09-11 Ngk Insulators, Ltd. Structure poreuse pour contact de fluides
DE4206812A1 (de) * 1991-03-06 1992-09-17 Nissan Motor Motorabgasfilter
EP0512659A2 (fr) * 1991-05-06 1992-11-11 W.R. Grace & Co.-Conn. Bande de feuille métallique mince ondulée
EP1024255A2 (fr) * 1999-01-29 2000-08-02 Oberland Mangold GmbH Structure de support pour un dispositif d'épuration de gaz d'échappement

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2733640C3 (de) * 1977-07-26 1981-04-30 Süddeutsche Kühlerfabrik Julius Fr. Behr GmbH & Co KG, 7000 Stuttgart Matrix für einen katalytischen Reaktor zur Abgasreinigung bei Brennkraftmaschinen
FR2695326B1 (fr) * 1992-09-08 1994-12-02 Strasbourg Ecole Nale Sup Arts Matrice métallique de réacteur catalytique pour le traitement des gaz de combustion.
CZ297854B6 (cs) 1995-12-13 2007-04-18 Ecocat Oy Katalytický konvertor
DE19704689A1 (de) * 1997-02-07 1998-08-13 Emitec Emissionstechnologie Wabenkörper mit im Inneren freiem Querschnittsbereich, insbesondere für Kleinmotoren
US6001314A (en) * 1997-09-15 1999-12-14 General Motors Corporation Catalytic converter housing with deep drawn shells
DE19922356C2 (de) * 1999-05-14 2001-06-13 Helmut Swars Wabenkörper

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5843238A (ja) * 1981-09-10 1983-03-12 Ngk Spark Plug Co Ltd セラミツクハニカム構造体とその製造法
EP0154516A2 (fr) * 1984-02-28 1985-09-11 Ngk Insulators, Ltd. Structure poreuse pour contact de fluides
DE4206812A1 (de) * 1991-03-06 1992-09-17 Nissan Motor Motorabgasfilter
EP0512659A2 (fr) * 1991-05-06 1992-11-11 W.R. Grace & Co.-Conn. Bande de feuille métallique mince ondulée
EP1024255A2 (fr) * 1999-01-29 2000-08-02 Oberland Mangold GmbH Structure de support pour un dispositif d'épuration de gaz d'échappement

Also Published As

Publication number Publication date
CN101316995A (zh) 2008-12-03
DE112006003187T5 (de) 2008-10-09
US20070122318A1 (en) 2007-05-31

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